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1 Bio-Algorithms and Med-Systems

1 2024

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Advancements in Maxillofacial Reconstruction: Design and Manufacturing Using Electron Beam Powder Bed Fusion (PBFEB/M)

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Szymczyk-Ziółkowska P. , Rusińska M. , Ziółkowski G. , Kobiela K. , Sekuła K. , Kęszycki D. , Miner-Kordasiewicz A.

Bio-Algorithms and Med-Systems

2024

tom Vol. 20, no. 1

49--61

Objective: Maxillofacial injuries often necessitate complex reconstructive surgeries, requiring the design and fabrication of patient-specific implants (PSIs) to restore functionality and aesthetics. A 32-year-old male patient, who sustained a mandible injury, served as a case study. Methods: This study presents advancements in maxillofacial reconstruction through the application of Electron Beam Powder Bed Fusion (PBF-EB/M), an additive manufacturing (AM) technique, in the creation of personalized jaw implants. CT scans were processed to develop a 3-D model of the patient's tissues, and Finite Element Analysis (FEA) was employed to assess mechanical behaviour. Results: The PSI, manufactured from a Ti6Al4V ELI alloy, exhibited suitable mechanical properties and biocompatibility. This work presents a workflow that clarifies the principles of designing, verifying and manufacturing PSIs for maxillofacial reconstruction. Conclusions: By integrating advanced imaging techniques, FEA simulations, and AM technologies, along with post-processing using CAM tools, the feasibility of producing personalized medical devices with modern manufacturing methods that offer enhanced design flexibility can be assessed. This includes highlighting both the potential benefits and challenges of the proposed approach.